N405CK

Part: WARNING LIGHT — ILLUMINATED · airframe 59,193 hrs · 41,541 cycles

ON THE RUNWAY CLEARED FOR TAKE-OFF, PER TAKE-OFF, AIRCRAFT WAS NOT MOVING, THROTTLE WAS NOT ADVANCING. CARGO DOOR ARMED LIGHT ILLUMINATED, REJECTED THE TAKE-OFF AND ADVISED TOWER NEEDED TO EXIT RUNWAY. WHEN EXCITED THE RUNWAY AND SET THE PARKING BRAKE THE LIGHT EXTINGUISHED AND NEVER CAME BACK ON. PERFORMED OPS CHECK OF THE MAIN CARGO DOOR IAW AEI SMM 52-33-01, OPS CHECKED GOOD.

Part: LANDING — CORRODED (ZONE 200) · corrosion level 2 · airframe 59,118 hrs · 41,485 cycles

FUSELAGE FWD ACCESS DOOR CUTOUT AFT BULKHEAD STA 227.5 RBL 3 LOWER CHORD HAS EVIDENCE OF CORROSION.

Part: INTERCOSTAL — CORRODED (ZONE 200) · corrosion level 2 · airframe 59,118 hrs · 41,485 cycles

INTERCOSTAL IN FORWARD ACCESS DOOR SURROUND AT STA 222 - 227.8 BL0 HAS EVIDENCE OF CORROSION.

Part: FLOOR SUPPORT — DAMAGED (ZONE 200) · airframe 59,118 hrs · 41,485 cycles

AFT PIT FLOOR SUPPORT DAMAGED AT STA 727F LBL 18".

Part: FRAME — DAMAGED (ZONE 200) · corrosion level 2 · airframe 59,118 hrs · 41,485 cycles

E/E BAY BILGE FRAME AT STA 360 AND APPROX BETWEEN STRINGERS S28R TO S29R DAMAGED WHERE FRAME MEETS FUSELAGE SKIN.

Part: FLOOR SUPPORT — DAMAGED (ZONE 100) · corrosion level 2 · airframe 59,118 hrs · 41,485 cycles

FWD CARGO BILDGE LT C-TRACK DAMAGED AT STA 500C BL-S-26

Part: FLOOR SUPPORT — CORRODED (ZONE 100) · corrosion level 2 · airframe 59,118 hrs · 41,485 cycles

AFT PIT STA 945 RBL 14" FLOOR SUPPORT HAS EVIDENCE OF CORROSION.

Part: ANTI-ICE VALVE — INOPERATIVE (ZONE 600) · airframe 59,074 hrs · 41,467 cycles

RIGHT VALVE OPEN, THERMAL ANTI-ICE VALVE REMAINS ON IN FLIGHT, SWITCH IN OFF POSITION. REMOVED AND REPLACED RIGHT WING ANTI-ICE SHUTOFF VALVE IAW B737 AMM 30-11-11, OPS CHECK GOOD NO DEFECTS NOTED.

Part: FLOORBEAM — CORRODED (ZONE 100) · corrosion level 2 · airframe 58,315 hrs · 40,969 cycles

EVIDENCE OF CORROSION ON MAIN DECK FLOOR BEAM UPPER SURFACE AT STA 947.5 RBL 40.

Part: UNKNOWN — CORRODED (ZONE 100) · corrosion level 2 · airframe 58,315 hrs · 40,969 cycles

EVIDENCE OF CORROSION FOUND LH W/W CEILING CHORD LOWER SURFACE AT APPROX STA 707 LBL 5.

Part: FLOORBEAM — PUNCTURED (ZONE 200) · airframe 58,315 hrs · 40,969 cycles

MAIN DECK FLOOR BEAM PUNCTURED AT VERTICAL WEB FOUND IN AFT CARGO PIT AT STA 727C RBL 5.

Part: SWITCH — DIRTY (ZONE 200) · airframe 57,704 hrs · 40,409 cycles

CARGO DOOR LIGHT ILLUMINATED AT FL 330, DESCENDED FOR LANDING, CARGO DOOR LIGHT EXTINGUISHED AT ABOUT 8000 FT MSL AND REMAINED OUT. LANDED AT KMEM FOR AN UNSCHEDULED LANDING. CORRECTIVE ACTION & OTHER PERTINENT INFORMATION: CLEANED & INSPECTED CARGO DOOR SWITCHES IAW AEI AMM SUP 52-33-01, OPS CHECK GOOD NO DEFECTS NOTED AT THIS TIME.

Part: PRESSURE SYSTEM — FAILED · airframe 57,508 hrs · 40,215 cycles

CABIN ALTITUDE ALERT ON LOG PAGE 737-001-7778 AND SECOND FLIGHT LP 737-001-7779. CORRECTIVE ACTION & OTHER PERTINENT INFORMATION: LP 7778, R&R CABIN PRESSURE CONTROLLER IAW B737 AMM 21-31-21, OPS CHECKS GOOD NO DEFECTS NOTED. CORRECTIVE ACTION ON LP 7779 TROUBLESHOT AND FOUND #2 ENGINE NOT PUTTING OUT BLEED AIR, FOUND WIRE HARNESS FOR BLEED AIR REGULATOR NOT SECURE, SECURED WIRE HARNESS IAW SWPM 20-10-11, PERFORMED ENGINE RUNS IAW B737 AMM 71-00-00, SYSTEM OPS CHECKED GOOD

Part: WIRE — BROKEN (TE FLAPS) · airframe 56,936 hrs · 39,671 cycles

ON APPROACH FLAPS WOULD NOT EXTEND PAST 25 WITH FLAPS SELECTED 30, UPON LANDING FLAPS EXTENDED TO 30. R & R RELAY R123 IAW BSWPM 20-81-22 & ADJUSTED LT & RT FLAP TRANSMITTERS IAW AMM 27-51-00. PERFORMED FLAP POSITION INDICATING TEST IAW AMM 27-58-01. OPS CHECK GOOD. PERFORMED TRAILING EDGE TROUBLESHOOTING IAW AMM 27-61-00. FOUND NR 4 & 5 FLAP JACKSCREW WORN, NR 2 FLAP TRANSMISSION BINDING, R & R RIG & OPS CHECK GOOD. COMPLETED STEPS 9 - 15 IAW AMM 27-51-00, FOUND LT INBD FLAP DRIVE MECH. ROLLER BROKEN. R & R BEARING, RIGGED FLAP HANDLE, FLAP BODY CABLES, & FOLLOW CABLES IAW AMM 27-51-00. OPS CHECK GOOD. R & R LT FLAP TRANSMITTER IAW AMM 27-58-12. OPS CHECK GOOD. R & R TRAILING EDGE CONTROL VALVE IAW AMM 27-51-79, RIGGED, OPS & LEAK CHECK GOOD. R & R FLAP PRIORITY VALVE, FLAP BYPASS VALVE & RIGHT WING FLAP POSITION TRANSMITTER, ALL RIGGED, OPS & LEAK CHECK GOOD IAW AMM 27-51-24, 27-51-82, & 27-58-12. R & R RT OTBD FORE FLAP INBD TRACK ROLLERS IAW AMM 20-50-11. OPS CHECK GOOD IAW AMM 27-51-00. FLAP LOAD LIMIT SWITCH CONNECTOR DISCONNECTED, CAPPED & STOWED FOR TROUBLESHOOTING. TRANSFERRED TO DMI# 40500021 IAW KC2 MEL 27-8-2, CAT C,. R & R FLAP DRIVE UNIT IAW AMM 27-51-54, OPS & RIG CHECK GOOD. R & R TRAILING EDGE FLAP POSITION INDICATOR IAW AMM 27-58-41, OPS CHECK GOOD. FLAP LOAD LIMITER SOLENOID CONNECTOR DISCONNECTED, CAPPED & STOWED FOR TROUBLESHOOTING. RECONNECTED FLAP LOAD LIMITER SOLENOID CONNECTOR & PERFORMED OPS CHECK IAW AMM 27-51-79. OPS CHECK GOOD. R & R NR 3, 4, 5 & 6 TE FLAP TRANSMISSION ASSY. CLEANED INSPECT, LUBED ALL FLAP TRACKS, TORQUE TUBES, CARRIAGES, & BEARINGS. REPLACED WORN COLLARS & BEARINGS. RIG, LEAK, & OPS CHECK GOOD IAW AMM 27-51-04, 27-51-34, 27-51-29. R & R LT & RT POSITION TRANSMITTERS, FLAP POSITION INDICATORS, FLAP ALTERNATE DRIVE UNIT, FLAP RELIEF POWER, & LOGIC CARDS, FLT CONTROL MODULE P5-3, & REPAIRED FLAP 10 SWITCH WIRING IN THE LT WW, REMOVE DETECTION DEVICES, INSTALLED IAW MM KCA-KAE-21-000A-05B, FOUND CONNECTOR NOT FULLY SEATED. REINSTALLED CONNECTOR IAW AMM 20-60-00. OPS CHECK GOOD. CHECKED WIRING ON FLAP ASYMMETRY EWIS IAW BSWPM 20-11-04 & WDM 27-52-01. REPAIRED BROKEN WIRES IAW BSWPM 20-10-13 & WDM 27-52-01. OPS CHECK GOOD. R & R S602 FLAP ASYMMETRY TEST SWITCH IAW AMM 27-51-00 & SRM 51-40-02. OPS CHECK GOOD IAW AMM 27-51-00, TE FLAPS CHECK GOOD IAW AMM 27-51-00, 32-32-00, 32-33-00, 34-31-02, & 34-32-01. NO DEFECTS NOTED. R & R NR 1, 7, AND 8 FLAP TRANSMISSIONS & BALL SCREWS IAW AMM 27-51-71. OPS CHECK GOOD IAW AMM 27-51-00. FUNCTIONAL EVAL FLT SATISFACTORY.

Part: INDICATOR — FAILED (TE FLAP SYSTEM) · airframe 56,256 hrs · 39,032 cycles

ON TAKEOFF FLAPS SELECTED UP, THE FLAP INDICATOR SPLIT WITH ONE FLAP AT 5 AND THE OTHER AT 1, FLAP STOPPED MOVING. CORRECTIVE ACTION & OTHER PERTINENT INFORMATION: R&R FLAP POSITION INDICATOR, OPS CHECK GOOD IAW B737 AMM 20-50-11 AND 27-58-01 REMOVED E1-1 RACK TO REPAIR DAMAGED WIRE INSULATION IAW BOEING SWPM 20-10-13, REINSTALLED E1-1 RACK IAW B737 SRM 51-40-02 NO DEFECTS NOTED

Part: FLASHLIGHT — INOPERATIVE (CABIN) · airframe 55,606 hrs · 38,510 cycles

2 EA. FLIGHT ATTENDANT, CAPTAINS, & 1ST OFFICERS EMERGENCY FLASHLIGHTS DO NOT BLINK

Part: FRAME — CRACKED (BS 727B) · airframe 55,606 hrs · 38,510 cycles

UPPER EDGE OF FRAME HAS A CRACK AFT PIT BILGE STA 727B BL 0

Part: FRAME — CRACKED (BS 967) · airframe 55,606 hrs · 38,510 cycles

FRAME CRACKED IN AFT PIT AT EXISTING TOOLING HOLE STA 967 RBL 1

Part: LIGHT — INOPERATIVE (CABIN) · airframe 55,606 hrs · 38,510 cycles

EXIT LIGHT FWD OF R1 DOOR DOES NOT ILLUMINATE

Part: REGULATOR — MALFUNCTIONED (BLEED AIR SYS) · airframe 55,210 hrs · 38,189 cycles

DURING CLIMB THE #2 BLEED TRIP OFF LIGHT ILLUMINATED. R&R HIGH STAGE REGULATOR IAW AMM 36-11-86. GROUND OPS AND LEAK CHECKED GOOD.

Part: STRINGER CLIP — CRACKED (FUSELAGE) · airframe 54,937 hrs · 37,982 cycles

STRINGER CLIP CRACKED STA 277 STR 15R.

Part: SKIN — DAMAGED (FUSELAGE) · airframe 54,937 hrs · 37,982 cycles

SCRIBELINE AFT CARGO DOOR SURROUND STA 787 STR 22R.

Part: SKIN — CRACKED (FUSELAGE) · airframe 54,937 hrs · 37,982 cycles

L1 DOOR CRACK INDICATION STA 303 & WL 260 UPPER HINGE CUTOUT.

Part: SKIN — CRACKED (FUSELAGE) · airframe 54,937 hrs · 37,982 cycles

L1 DOOR CRACK INDICATION STA 303 & WL 236 LOWER HINGE CUTOUT.

Part: SKIN — CORRODED (RT WING) · corrosion level 2 · airframe 54,937 hrs · 37,982 cycles

RIGHT WING CORROSION OVERWING FILL PORT & ADAPTER.

Part: SKIN — CORRODED (RT WING) · corrosion level 2 · airframe 54,937 hrs · 37,982 cycles

RIGHT WING UPPER SKIN CORROSION 36" O/B OF WING ROOT WBL 107 & 12" AFT OF FRONT SPAR.

Part: SPAR — CORRODED (VERTICAL STAB) · corrosion level 2 · airframe 54,937 hrs · 37,982 cycles

VERTICAL STAB FRONT SPAR RT CORROSION MID BUSHING.

Part: SKIN — CORRODED (VERTICAL STAB) · corrosion level 2 · airframe 54,937 hrs · 37,982 cycles

VERTICAL STAB FRONT SPAR CORROSION LT MID BUSHING.

Part: RIB — CORRODED (RT AILERON) · corrosion level 2 · airframe 54,937 hrs · 37,982 cycles

CORROSION ON RIGHT AILERON ON FWD SIDE OF FRONT SPAR 23" O/B AILERON I/B END WBL 417.25 & 425.75.

Part: LUG — CORRODED (ZONE 300) · corrosion level 2 · airframe 54,937 hrs · 37,982 cycles

CORROSION ON FORWARD FACE OF VERTICAL STAB FUSELAGE ATTACHMENT LT LUG.

Part: STRUCTURE — CORRODED (VERTICAL STAB) · corrosion level 2 · airframe 54,937 hrs · 37,982 cycles

NUT PLATE CORROSION IN VERTICAL STAB TRAILING EDGE FIN WL 110.

Part: WEB — CORRODED (FUSELAGE) · corrosion level 2 · airframe 54,937 hrs · 37,982 cycles

WALL TO FLOOR WEB CORROSION STA 847 & 867 RBL 70.

Part: ANGLE — CORRODED (FUSELAGE) · corrosion level 2 · airframe 54,937 hrs · 37,982 cycles

WALL TO FLOOR OUTER ANGLE CORROSION STA 807 RBL 70.

Part: SLAT — CORRODED (RT WING) · corrosion level 2 · airframe 54,937 hrs · 37,982 cycles

RT WING INTERIOR OF NR 5 SLAT WING STA 383.

Part: DOOR FRAME — CORRODED (FUSELAGE) · corrosion level 2 · airframe 54,937 hrs · 37,982 cycles

GALLEY SERVICE DOOR OPENING WEB STRUCTURE CORROSION FWD LOWER CORNER STA 294.5 RBL 48.

Part: STRINGER CLIP — CRACKED (FUSELAGE) · airframe 54,937 hrs · 37,982 cycles

STRINGER TIE CLIP @ STA 663.75 STR 10R CRACKED.

Part: STRINGER CLIP — CRACKED (FUSELAGE) · airframe 54,937 hrs · 37,982 cycles

STRINGER TIE CLIP STA 706 STR 10R.

Part: ACCESS PANEL — CORRODED (LE SLAT) · corrosion level 2 · airframe 54,937 hrs · 37,982 cycles

ACCESS PANEL 5244L ON NR 1 SLAT CORRODED.

Part: STRINGER CLIP — CRACKED (FUSELAGE) · airframe 54,937 hrs · 37,982 cycles

STRINGER TIE CLIP STA 685 STR 10R.

Part: STRINGER CLIP — CRACKED (FUSELAGE) · airframe 54,937 hrs · 37,982 cycles

STRINGER TIE CLIP @ STA 663.75 STR 10L CRACKED.

Part: SPAR — CORRODED (LT HORIZ STAB) · corrosion level 2 · airframe 54,937 hrs · 37,982 cycles

CORROSION ON LT STAB REAR SPAR LOWER SURFACE STAB STA 57.93 - 295.10.

Part: RIB — CORRODED (LT HORIZ STAB) · corrosion level 2 · airframe 54,937 hrs · 37,982 cycles

CORROSION ON LT STAB RIBS ST 24.9,39.02,66.54,4.07,121.59,149.12,176.64,195,213.32.

Part: WEB — CORRODED (FUSELAGE) · corrosion level 2 · airframe 54,937 hrs · 37,982 cycles

CORROSION ON NUTPLATES ON LT SIDE OF APU ACCESS STA 1090WE.

Part: FRAME — CRACKED (FUSELAGE) · airframe 54,937 hrs · 37,982 cycles

FRAME CRACK @ SUPPORT BRACKET.

Part: SKIN — CORRODED (LT WING) · corrosion level 2 · airframe 54,937 hrs · 37,982 cycles

LOWER WING SURFACE CORROSION, LEFT A/C BAY NEAR SECONDARY HEAT EXCHANGER.

Part: FRAME — CRACKED (FUSELAGE) · airframe 54,937 hrs · 37,982 cycles

FRAME CRACKED @ SUPPORT BRACKET.

Part: FRAME — CRACKED (FUSELAGE) · airframe 54,937 hrs · 37,982 cycles

FRAME CRACKED @ SUPPORT BRACKET.

Part: FRAME — CRACKED (FUSELAGE) · airframe 54,937 hrs · 37,982 cycles

FRAME CRACKED @ SUPPORT BRACKET.

Part: FRAME — CRACKED (FUSELAGE) · airframe 54,937 hrs · 37,982 cycles

FRAME CRACK @ SUPPORT BRACKET.

Part: FRAME — CRACKED (FUSELAGE) · airframe 54,937 hrs · 37,982 cycles

FRAME CRACKED @ SUPPORT BRACKET.

Part: FRAME — CRACKED (FUSELAGE) · airframe 54,937 hrs · 37,982 cycles

FRAME CRACKED @ SUPPORT BRACKET.

Part: FRAME — CRACKED (FUSELAGE) · airframe 54,937 hrs · 37,982 cycles

FRAME CRACK @ SUPPORT BRACKET.

Part: FRAME — CRACKED (FUSELAGE) · airframe 54,937 hrs · 37,982 cycles

FRAME CRACK @ SUPPORT BRACKET.

Part: FRAME — CRACKED (FUSELAGE) · airframe 54,937 hrs · 37,982 cycles

FRAME CRACKED @ SUPPORT BRACKET.

Part: FRAME — CRACKED (FUSELAGE) · airframe 54,937 hrs · 37,982 cycles

FRAME CRACKED @ SUPPORT BRACKET.

Part: FRAME — CRACKED (FUSELAGE) · airframe 54,937 hrs · 37,982 cycles

FRAME CRACKED @ SUPPORT BRACKET STA 440 RT BETWEEN STR 8 - 9.

Part: FRAME — CRACKED (FUSELAGE) · airframe 54,937 hrs · 37,982 cycles

FRAME CRACKED @ SUPPORT BRACKET.

Part: FRAME — CRACKED (FUSELAGE) · airframe 54,937 hrs · 37,982 cycles

FRAME CRACKED @ SUPPORT BRACKET.

Part: FRAME — CRACKED (FUSELAGE) · airframe 54,937 hrs · 37,982 cycles

FRAME CRACKED @ SUPPORT BRACKET.

Part: FRAME — CRACKED (FUSELAGE) · airframe 54,937 hrs · 37,982 cycles

FRAME CRACKED @ STA 480 RT BETWEEN STR 8 - 9.

Part: FRAME — CRACKED (FUSELAGE) · airframe 54,937 hrs · 37,982 cycles

FRAME CRACKED @ SUPPORT BRACKET.

Part: FRAME — CRACKED (FUSELAGE) · airframe 54,937 hrs · 37,982 cycles

INSULATION BLANKET STUD HOLE HAS CRACK STA 360 STR 20R.